FLYING SPLICE ADHESIVE TAPE

Abstract: A flying splice tape (10, 110) for holding down a leading edge portion (44) of an outer layer (46) of a following roll of web material (48) and for facilitating the splicing of the leading edge portion to a portion (54) of a leading roll of web material which is being advanced includes a tape substrate (12, 112) having a first side (14, 114) and a second side (16, 116). The tape substrate has, on its first side, a first portion (18, 118), a second portion (22, 122) and an intermediate portion (26, 126) therebetween. A weakened section (25, 125) is preferably defined by a plurality of spaced cuts (28, 128) along the intermediate portion (26, 126). The first portion (18, 118) on the first side (14, 114) of the tape substrate (12, 112) includes a first adhesive layer (34, 134) being spaced from the weakened section (25, 125) extends towards a first edge (20, 125) of the tape substrate, while the second portion (22, 122) on the same first side (14, 114) includes a second adhesive layer (36, 136) extending from adjacent the weakened section (25, 125) towards the second, opposite edge (24, 124). The intermediate portion (26, 126) of the first side of the tape substrate is free of adhesive. The second side (16, 116) of the tape substrate (12, 112) includes a third adhesive layer (38, 138) which extends from the cuts (28, 128) towards the first edge (20, 120) of the tape substrate (12, 112). A remaining portion (40, 140) of the second side (16, 116) of the tape substrate (12, 112) is free of adhesive.

Description: FLYING SPLICE ADHESIVE TAPE BACKGROUND OF THE INVENTION The present invention relates generally to web splicing. In particular, the present invention is a flying splice, pressure sensitive, adhesive tape that is used to splice a leading edge of a new roll of web material to a trailing edge of an expiring roll of web material. In the newspaper and magazine publishing industry, the lengths of web material (i.e., paper), from which individual newspapers or magazines are printed, are contained on rolls (i.e., elongate members). Typically, the length of web material of a roll is continuous from its trailing edge at the core of the roll to its leading edge at the periphery of the roll. The length of web material from an individual roll is fed into a printing apparatus where print and/or pictures are applied to the web material in a continuous, automated process. Next, the length of web material is cut into sheets of desired size and then these sheets are assembled into individual newspapers or magazines. The cutting of the sheets and the assembling of the sheets into their final print medium format is once again, a continuous, automated process. Typically, during the continuous process of printing, cutting and assembling of the print medium, the length of web material travels at speeds of between 2000 and 3000 feet per minute. Hence, large numbers of individual newspapers or magazines can be produced in a relatively short period of time. A disadvantage in the use of the rolls of web material occurs when splicing a leading edge of a "new" roll of web material to the trailing edge of an "old" roll of web material currently traveling through the continuous printing, cutting and assembling process. This type of new-to-old roll connection is referred to as a "flying splice", and is a splice made between an expiring roll of web material and a new roll of web material in a continuous manner without reducing either the equipment speed or the speed of the web. Typically, to splice the leading edge of the new roll to the trailing edge of the old roll, one or more pieces of adhesive tape are manually applied to the leading edge of the new roll of web material. Pressure sensitive adhesive on a bottom surface of the tape secures the tape to the leading edge. With the tape secured to the leading edge of the new roll, the leading edge of the new roll iβ brought into contact with the old roll, where pressure sensitive adhesive on the top surface of the tape secures the leading edge of the new roll of web material to the trailing edge of the old roll of web material. During this splicing process, the old roll is traveling at a speed of between 2000 and 3000 feet per minute and acts to continuously and automatically thread the web material of the new roll into the apparatus performing the printing, cutting and assembling process. Canadian Patent Application 2,025,473 to Josef et al. discloses one such adhesive splice tape used to splice an angled leading edge of a new roll of web material to an expiring roll of web material. The splice tape is divided into three zones. A first outer zone of the splice tape has both an upper adhesive layer and a lower adhesive layer. A central zone of the splice tape has. neither an upper or lower layer of adhesive, but is formed with a longitudinal perforation. A second outer zone of the splice tape has only a lower adhesive layer. The lower adhesive layer of the first outer zone secures the splice tape to a leading edge of a new roll of web material. The leading edge of the renewal web material is cut at an angle of less than ninety degrees as measured between the roll off direction of the web material and the leading edge. The lower adhesive layer of the second outer zone secures the splice tape to that portion of the web material that is immediately adjacent the angled leading edge and forms the next underlying layer of web material. With the lower adhesive layers secured to the web material, the longitudinal perforation of the central zone of the splice tape is aligned with the angled leading edge. The upper adhesive layer of the first outer zone helps to secure the angled leading edge of the renewal roll to the expiring roll to initiate the roll changing procedure. The longitudinal perforation permits separation of the splice tape along the angled leading edge of the web material to complete the roll changing procedure. This splice tape and method of preparing a new (i.e., replacement) roll of web material has some disadvantages. The splice tape is applied to a leading edge (of a new roll of web material) that is cut at an angle of less than ninety degrees as measured between the roll off direction of the web material and the leading edge. The splice tape is applied in this manner so that the perforations tear gradually starting at a forward end (as determined by the direction of travel of the web) of the angled leading edge and traveling along the leading edge until separation of the splice tape is complete at the rearward end (as determined by the direction of travel of the web) of the angled leading edge. However, since the web material leading edge is angled, forces applied to printing drums of printing equipment by the web material as the angled leading edge passes over a printing drum are not directed perpendicular to a generatrix of the drum that is parallel to a longitudinal axis of the drum. The forces effected on the drum by the angled leading of the web material as it passes over the drum, would be directed generally perpendicular to the angled leading edge. These angled forces (i.e., forces that are not applied to the drum perpendicular to a drum generatrix that is parallel to the longitudinal axis of the drum) cause the drum to cant or tilt inducing surface stresses on the printing plate (i.e., blanket) of the drum. These induced surface stresses, in turn, decrease the operational life of the printing plate of the drum when compared to a web material whose leading edge is parallel to a longitudinal axis of the roll on which the web material is contained. The forces effected by this nonangled leading edge of web material are applied to the printing drum generally perpendicular to a drum generatrix that is parallel to the longitudinal axis of the drum. Thus, the stresses on the surface (i.e., printing plate) of the drum (caused by these leading edge forces) are directed only circumferentially about the drum, hence, premature wear due to canting or tilting of the printing drum (caused by an angled leading edge) are eliminated. There are further disadvantages to the splice tape and method of preparing a new roll of web material as disclosed by the Canadian Patent Application. The upper adhesive layer of the first outer zone and the lower adhesive layer of the second outer are spaced from the longitudinal perforation by central zone regions that have neither an upper or lower layer of adhesive. These central zone regions create splice tape flaps or tails that are not secured to the web material. These unsecured splice tape tails may catch on printing line equipment (especially printing, sheeting and stacking equipment) causing the web material to tear or jam, consequently halting printing line production. In addition, the angled leading edge of the new roll of web material results in an expiring roll whose spliced, free tail web material length is greater than the spliced free tail web material length of a new roll of web material implementing a nonangled leading edge (i.e., a leading edge the is parallel to a longitudinal axis of the new roll of web material). Typically, once the new roll web material has been joined to the web material of the expiring roll and splice tape separation has occurred, the web material of the expiring roll is cutoff to a minimal, predetermined length immediately past the splice tape creating a free tail of expiring web material that is not secured to the new roll web material. This unsecured web material free tail may catch on printing line equipment (especially printing, sheeting and stacking equipment) causing the web material of the new roll to tear or jam, consequently halting printing line production. An angled leading edge creates a free tail that includes a triangular shaped region of expiring web material defined between the forward and rearward ends of the splice tape, and a rectangular shaped region of expiring web material defined between the rearward end of the splice tape and the expiring web material cutoff. The use of a new roll of web material with a nonangled leading edge creates a free tail that only includes a rectangular shaped region of expiring web material defined between the rear edge of the splice tape and the expiring web material cutoff. Hence, the nonangled leading edge would minimize the amount of expiring web material free tail that may catch on printing line equipment. There is a continuing need for flying splice adhesive tape that can be processed through all the equipment on a printing line including sheeters and stackers. Specifically there is a need for flying splice adhesive tape that eliminates any unsecured splice tape regions which could catch on printing, sheeting and stacking equipment causing tearing of the web material. Moreover, there is a need for flying splice adhesive tape that is applicable to a leading edge of web material, that is parallel to a longitudinal axis of the roll upon which the web material is contained, to reduce printing drum wear, and minimize the amount of expiring web material free tail that could catch on and jam printing line equipment. In addition, the flying splice adhesive tape should be capable of being applied to the renewal roll of web material quickly by hand, by a manually operable tape dispenser or by an automatic tape application apparatus. DISCLOSURE OF THE INVENTION The present invention is a flying splice tape for holding down a leading edge portion of an outer layer of a following roll of web material and for facilitating the splicing of the leading edge portion to a portion of a leading roll of web material which is being advanced. The splice tape includes a tape substrate having a first side and a second side. The tape substrate has, on its first side, a first portion adjacent a first edge of the tape substrate, a second portion adjacent a second edge of the tape substrate and an intermediate portion therebetween. A weakened section is preferably defined by a plurality of spaced cuts in the tape substrate along the intermediate portion of the tape substrate. The first portion of the first side of the tape substrate has a first adhesive layer that is spaced from the cuts and extends towards the first edge of the tape substrate. The second portion of the first side of the tape substrate has a second adhesive layer that is adjacent to the cuts and extends towards the second edge of the substrate, while the intermediate longitudinal portion of the first side of the tape substrate is free of adhesive. The second side of the tape substrate has a third adhesive layer that extends from the cuts towards the first edge of the substrate. A remaining portion of the second side of the tape substrate is free of adhesive. The first side of the tape substrate is adapted to be adhered to the following roll of web material, with the first longitudinal portion adhered to the leading edge portion of the outer layer via the first adhesive layer, and the second longitudinal portion adhered, via the second adhesive layer, to a portion of the roll of web material that is immediately adjacent the leading edge portion and forms the next underlying layer of the following roll of web material. The longitudinally extending weakened section of the intermediate longitudinal portion is aligned with and adjacent to the leading edge portion of the outer layer of the following roll when the tape substrate is secured to the following roll of web material. The third adhesive layer is adapted to adhere to the portion of the leading roll of web material, to cause separation of the splice tape along the longitudinally extending weakened section and splicing of the following roll of web material to the portion of the leading roll of web material. The plurality of cuts define a separation line of the longitudinally extending weakened section. This separation line in one embodiment is substantially parallel to the leading edge portion and a longitudinal axis of the following roll of web material. A portion of the third adhesive layer on the second side of the substrate extends past the leading edge portion to facilitate a adhesion of the third adhesive layer to the portion of the leading roll of web material and thereby separation of the splice tape at the separation line. This flying splice adhesive tape can be processed through all the equipment on a printing line including sheeters and stackers. In addition, since the second and third adhesive layers are immediately adjacent to the plurality of cuts, the amount of unsecured splice tape tail is minimized which lessens the likelihood that the splice tape tails could jam in printing and finishing line equipment (such as sheeters and stackers) or catch in printing equipment affecting tracking of the web material, causing web material wrinkles, web breaks or tear offs that could affect final print quality. Moreover, this flying splice adhesive tape is applicable to a leading edge of web material, that is parallel to a longitudinal axis of the roll upon which the web material is contained, which reduces printing drum wear as the leading edge passes over the printing drum since leading edge forces are directed perpendicular to a printing drum generatrix which is parallel to a longitudinal axis of the drum. The nonangled leading edge also minimizes the amount of expiring web material free tail that could catch on and jam printing line equipment when compared to splice tape requiring an angled leading edge. In addition, since the third adhesive layer extends past the first adhesive layer, the splice tape presents a stepwise increase in splice tape thickness to the printing drums, which further reduces printing drum stresses that would otherwise exist if the first and third adhesive layers had the same starting point and presented an abrupt change in splice tape thickness to the printing drum. Using this splice tape with a following roll of web material having a leading edge portion that is parallel to the longitudinal axis of the roll allows tension to be applied uniformly across the web material when the "new-to-old" splice is made and as the splice travels through the printing, cutting and assembling machinery. Uniform web material tension reduces tension upsets thereby resulting in a straight tracking web material which reduces accidental web material breakage. In addition, since the tape is useable with a following roll of web material having a leading edge portion that is parallel to the longitudinal axis of the roll, less tape has to be applied to the leading edge, thereby reducing waste. Moreover, applying the tape to the leading edge portion of the roll of web material that is parallel to the roll axis is easier for both manual and automatic application when compared to applying a splice tape to an angled leading edge. The flying splice adhesive tape can be applied to the following roll of web material by hand, by a manually operable tape dispenser or by an automatic tape application apparatus. When compared to the current system of manual application employing a plurality of paster tabs, paster tapes and splice flags, this splice tape can be accurately and consistently applied to a leading edge from one roll of web material to the next. BRIEF DESCRIPTION OF THE DRAWINGS The invention is further described with reference to the accompanying drawings, where like numbers refer to like parts in several views. FIG. 1 is a perspective view of an upper surface of a flying splice adhesive tape in accordance with the present invention with a release liner shown being peeled away. FIG. 2 is a perspective view of a lower surface of the flying splice adhesive tape shown in FIG. 1. FIG. 3 is a sectional view taken along line 3-3 in FIG. 1. FIG. 4 is an elevational view of an upper surface of a further embodiment of the flying splice adhesive tape shown in FIG. 1. FIG. 5 is an elevational view of an upper surface of a still further embodiment of the flying splice adhesive tape shown in FIG. 1. FIG. 6 is a perspective view of an upper surface of an alternative embodiment of a flying splice adhesive tape in accordance with the present invention with a release liner shown being peeled away. FIG. 7 is a perspective view of a lower surface of the alternative flying splice adhesive tape shown in FIG. 5. FIG. 8 is a sectional view taken along line 8-8 in FIG. 6. FIG. 9 is a side elevational view partially in section illustrating the flying splice adhesive tape of FIGS. 1 and 2 applied to a renewal roll of web material with the renewal roll positioned adjacent to an expiring roll of web material. FIG. 10 is a side elevational view partially in section similar to FIG. 9 illustrating the initiation of a roll changing procedure. FIG. 11 is a side elevational view partially in section similar to FIG. 9 illustrating the successful completion of the roll changing procedure. These drawing figures are provided for illustrative purposes only and are not drawn to scale, nor should they be construed to limit the intended scope and purpose of the present invention. DETAILED DESCRIPTION A flying splice adhesive tape 10 in accordance with the present invention is illustrated generally in FIGS. 1-3. The splice tape 10 includes a tape substrate 12 having a first side 14 (see FIG. 2) and a second side 16 (see FIG. 1). As seen in FIG. 2, the tape substrate 12 has, on its first side 14, a first longitudinal portion 18 adjacent a first longitudinal edge 20, a second longitudinal portion 22 adjacent a second longitudinal edge 24 and an intermediate longitudinal 5 portion 26 therebetween. A longitudinally extending weakened section 25 extends along the intermediate longitudinal portion 26 of the tape substrate 12. The weakened section 25 is defined by a plurality of spaced linear cuts 28 through the tape substrate 12 along the intermediate longitudinal portion 26. The linear cuts 28 10 are oriented substantially parallel to the first and second longitudinal edges 20 and 24 and are located closely adjacent the second longitudinal portion 22. Located between adjacent linear cuts 28 are stress cuts 29 that extend through the tape substrate 12 along the intermediate longitudinal portion 26. The stress cuts 15 29 further define the weakened section 25 of the splice tape 10. The stress cuts 29 are oriented substantially parallel to the linear cuts 28 and are offset therefrom so as to be located closer to the second longitudinal portion 22 than the linear cuts 28. The linear cuts 28 and the stress cuts 29 define a splice tape 0 separation line of the longitudinally extending weakened section 25. The stress cuts 29 relieve stress in the tape substrate 12 between the plurality of linear cuts 28, and thereby aid in defining the tape separation line so that tape separation occurs substantially along the linear cuts 28. Preferably, the weakened 5 section 25 of the intermediate longitudinal portion 26 is defined by the linear cuts 28 and the stress cuts 29 which extend all the way through the tape substrate 12. However, the weakened section 25 may be defined by a plurality of score lines or other means on the intermediate portion 26 of the tape substrate 12 to induce 0 tape separation along a desired separation line. As seen in FIGS. 2 and 3, the first longitudinal portion 18 of the first side 14 of the tape substrate 12 has a first pressure sensitive adhesive layer 34. The second longitudinal portion 22 of the first side 14 of the tape substrate 12 has a second pressure 5 sensitive adhesive layer 36, while the intermediate longitudinal portion 26 of the first side 14 of the tape substrate 12 is free of adhesive. Preferably, the adhesive free intermediate portion 26 is formed by the selective application of the first and second adhesive layers 34 and 36 to only the first and second portions 18 0 and 22, respectively, of the tape substrate 12. Hence, the intermediate portion 26 of the tape substrate 12 lacks any adhesive layer and is therefore "free of adhesive". Alternatively, an adhesive layer may be applied to all of the first side 14 of the tape substrate 12 with the adhesive free intermediate portion 26 formed by applying a suitable deadening substrate over the adhesive layer in the desired location of intermediate portion 26; or by selectively masking the adhesive layer, in the desired location of intermediate portion 26, using a spray material. As seen in FIG. 1, the second side 16 of the tape substrate 12 has a third pressure sensitive adhesive layer 38 that is spaced from the first longitudinal edge 20 by an end margin 39. The third pressure sensitive adhesive layer 38 extends between the end margin 39 and the linear cuts 28. Both the end margin 39 and a remaining portion 40 of the second side 16 of the tape substrate 12 that extends between the linear cuts 28 and the second longitudinal edge 24 are free of adhesive (in the manner previously described with respect to intermediate portion 26). As seen best in FIGS. 1 and 2, the third adhesive layer 38 and the second adhesive layer 36 are directly adjacent the linear and stress cuts 28 and 29 to minimize the area of non adhesive coating. The second side 16 of the tape substrate 12 is covered by a removably affixed release liner 42. The liner 42 allows the splice tape 10 to be wound upon a roll since the liner 42 prevents adjacent layers of the tape substrate 12 from becoming permanently adhesively secured to one another. The end margin 39 permits the liner 42 to be readily removed when the flying splice adhesive tape 10 is to be applied by hand or a manually operable tape dispenser. In addition, removal of the liner 42 from the first longitudinal edge 20 at the end margin 39 reduces the amount of stress placed on the linear and stress cuts 28 and 29 eliminating accidental separation of the splice tape 10 along the linear and stress cuts 28 and 29 during manual removal of the liner 42. As seen in FIG. 4, the flying splice adhesive tape 10 may optionally include a visual guide line 41 printed on the second side 16 of the tape substrate 12 so as to be located immediately adjacent first adhesive layer 34 on the first side 14 of the tape substrate 12. The visual guide line 41 is viewable through the release liner 42 when the release liner 42 is secured to the tape 10. The visual guide line 41 acts as a guide for the accurate positioning of the flying splice adhesive tape 10 on a leading edge of a following roll of web material when the tape 10 is to be applied by hand or a manually operable tape dispenser. The tape 10 should be secured to the leading edge of a following roll of web material with the visual guide line 41 located above and aligned with the leading edge. As seen in FIG. 5, the flying splice adhesive tape 10 may optionally include a visual guide region 43 printed on the second side 16 of the tape substrate 12 beneath the third pressure sensitive adhesive layer 38 and at the end margin 39. The visual guide region 43 extends from the first longitudinal edge 20 to an area located immediately adjacent the first adhesive layer 34 on the first side 14 of the tape substrate 12. The visual guide region 43 acts as a guide for the accurate positioning of the flying splice adhesive tape 10 on a leading edge of a following roll of web material when the tape 10 is to be applied by hand or a manually operable tape dispenser. The tape 10 should be secured to the leading edge of a following roll of web material with a guide edge 45 of the visual guide region 43 located above and aligned with the leading edge. The visual guide region 43 also provides a built-in optical flag so that photoelectric devices within the automatic splicing machinery can identify the leading edge of the renewal roll for speed match and expiring roll, web material, free tail length control. The visual guide region 43 can either be of a reflective or absorbative nature, but is preferably solid matt black with a minimum of 180 densitometer and is repulpable. A further embodiment of flying splice adhesive tape 110 in accordance with the present invention is illustrated generally in FIGS. 6-8. The splice tape 110 includes a tape substrate 112 having a first side 114 (see FIG. 7) and a second side 116 (see FIG. 6). As seen in FIG. 7, the tape substrate 112 has, on its first side 114, a first longitudinal portion 118 adjacent one longitudinal edge 120, a second longitudinal portion 122 adjacent a second longitudinal edge 124 and an intermediate longitudinal portion 126 therebetween. A longitudinally extending weakened section 125 extends along the intermediate longitudinal portion 126 of the tape substrate 112. The weakened section 125 is defined by a plurality of spaced V-shaped cuts 128 through the tape substrate 112 along the intermediate longitudinal portion 126. Located between adjacent V-shaped cuts 128 and adjacent to the first longitudinal portion 118 are stress cuts 129 that extend through the tape substrate 112 along the intermediate longitudinal portion 126. The stress cuts 129 are oriented substantially parallel to the first and second longitudinal edges 120 and 124. The V-shaped cuts 128 and the stress cuts 129 define a splice tape separation line of the longitudinally extending weakened section 125. The stress cuts 129 relieve stress in the tape substrate 112 between the plurality of V-shaped cuts 128, and thereby aid in defining the tape separation line so that tape separation occurs substantially along the V-shaped cuts 128. Located at an apex of each of the V-shaped cuts 128 are tape substrate portions 130. The tape substrate portions 130 prevent premature separation at the V- βhaped cuts 128 along the intermediate longitudinal portion 126: Preferably, the weakened section 125 of the intermediate longitudinal portion 126 is defined by the V-shaped cuts 128 and the stress cuts 129 which extend all the way through the tape substrate 112. However, the weakened section 125 may be defined by a plurality of score lines or other means on the intermediate portion 126 of the tape substrate 112 to induce tape separation along a desired separation line. As seen in FIGS. 7 and 8, the first longitudinal portion 118 of the first side 14 of the tape substrate 112 has a first pressure sensitive adhesive layer 134. The second longitudinal portion 122 of the first side 114 of the tape substrate 112 has a second pressure sensitive adhesive layer 136, while the intermediate longitudinal portion 126 of the first side 114 of the tape substrate 112 is free of adhesive (in the manner previously described with respect to intermediate portion 26). As seen in FIG. 6, the second side 116 of the tape substrate 112 has a third pressure sensitive adhesive layer 138 that is spaced from the first longitudinal edge 120 by an end margin 139. The third pressure sensitive adhesive layer 138 extends between the end margin 139 and the V-shaped cuts 128. Both the end margin 139 and a remaining portion 140 of the second side 116 of the tape substrate 112 that extends between the third pressure sensitive adhesive layer 138 and the second longitudinal edge 124 are free of adhesive (in the manner previously described with respect to intermediate portion 26). The second side 116 of the tape substrate 112 is covered by a removably affixed release liner 142. The liner 142 allows the splice tape 110 to be wound upon a roll since the liner 142 prevents adjacent layers of the tape substrate 112 from becoming permanently adhesively secured to one another. The end margin 139 permits the liner 142 to be readily removed when the flying splice adhesive tape 110 is to be applied by hand or a manually operable tape dispenser. In addition, removal of the liner 142 from the first longitudinal edge 120 at the end margin 139 reduces the amount of stress placed on the V-shaped and stress cuts 128 and 129 eliminating accidental separation of the splice tape 110 along the V-shaped and stress cuts 128 and 129 during manual removal of the liner 142. As with the first embodiment of the flying splice adhesive tape 10 shown in FIGS. 1-3, the flying splice adhesive tape 110 may optionally include a visual guide line (located immediately adjacent the first adhesive layer 134) that performs the same function as the visual guide line 41 of the tape 10, or a visual guide region (extending from the first longitudinal edge 120 to an area located immediately adjacent the first adhesive layer 134 on the first side 114 of the tape substrate 112) that performs the same function as the visual guide region 43 of the tape 10. The tape substrate 12, 112 of the flying splice adhesive tape 10, 110 is preferably formed of a suitable three inch wide fifty pound paper stock which is preferably rotary die cut with the cuts 28, 128, 29, 129. Alternatively, the cuts 28, 128, 29, 129 can be formed using laser cutting. The first 34, 134, second 36, 136 and third 38, 138 adhesive layers are then applied to the tape substrate 12, 112 such that the intermediate portion 26, 126, end margin 39, 139 and remaining portion 40, 140 lack any adhesive layer. The first 34, 134, second 36, 136 and third 38, 138 adhesive layers are preferably comprised of repulpable 3M 906 double sided tape available from Minnesota Mining and Manufacturing Co. of St. Paul Minnesota. Alternatively, the first 34, 134, second 36, 136 and third 38, 138 adhesive layers may be comprised of a non-repulpable 3M 465 double sided tape available from Minnesota Mining and Manufacturing Co. of St. Paul Minnesota or the selective application of adhesive transfer tape. The release liner 42, 142 is preferably comprised of a repulpable, silicone coated liner. It is to be understood that the adhesive layers may be applied directly to the tape substrate 12, 112 via a suitable pattern coating procedure with the intermediate portion 26, 126, end margin 39, 139 and remaining portion 40, 140 left free of any adhesive; or the adhesive layers may be applied to all of the first and second sides 14, 114, 16, 116 of the tape substrate 12, 112 with the adhesive free areas 39, 139, 40, 140, 26, 126 formed by applying a suitable deadening substrate over the adhesive in these areas or the selective masking of the adhesive layer by a spray material. As seen in FIG. 9, the splice tape 10 (it is to be understood that the following description also applies to the splice tape 110) is used to hold down a leading edge portion 44 of an outer layer 46 of a following roll of web material 48 to a portion 50 that is immediately adjacent the leading edge portion 44 and forms a next underlying layer 52 of the following roll of web material 48. The first side 14 of the tape substrate 12 is adapted to be adhered to the following roll of web material 48, with the first longitudinal portion 18 adhered to the leading edge portion 44, via the first adhesive layer 34; and the second longitudinal portion 22 adhered, via the second adhesive layer 36, to the portion 50 of the following roll of web material 48 that is immediately adjacent the leading edge portion 44. The longitudinally extending weakened section 25 of the intermediate longitudinal portion 26 as defined by the stress cuts 29 is aligned over and substantially parallel to the leading edge portion 44 of the outer layer 46 when the tape substrate 12 is secured to the following roll of web material 48. In this orientation of the tape substrate 12, at least a portion of the third adhesive layer 38 extends beyond the leading edge portion 44. As seen in FIGS. 9-11, the splice tape 10 also facilitates the splicing of the leading edge portion 44 of the following roll of web material 48 to a portion 54 of a leading roll of web material 56 which is being advanced. To splice the following roll of web material 48 to the leading roll of web material 56, first, the leading edge portion 44 is formed by cutting in a known manner. The leading edge portion 44 is cut so as to be substantially parallel to a longitudinal axis 58 of the following roll of web material 48 (i.e., the leading edge portion 44 is cut so as to be substantially perpendicular to the roll off direction of the web material). Next, the splice tape 10 is applied to the following roll of web material 48 such that the splice tape 10 holds the leading edge portion 44 down on the portion 50 that is immediately adjacent the leading edge portion 44 and forms a next underlying layer 52 of the following roll of web material 48. The tape substrate 12 or the adhesive layers 34, 36, 38 can be colored to visually contrast with the following roll of web material 48. The following roll of web material 48 is then rotated (in a known manner) counter-clockwise, as viewed in FIGS. 9-11 and represented by arrow 200, about its longitudinal axis 58 up to the speed of rotation (i.e., clockwise as viewed in FIGS. 9-11 and represented by arrow 202) of the leading roll of web material 56. Next, the following roll of web material 48 is moved into contact (as represented by arrow 204 in FIG. 9) with leading roll of web material 56 such that the third adhesive layer 38 adheres to the portion 54 of the leading roll of web material 56 (see FIG. 10). As seen in FIG. 11, adhesion of the third adhesive layer 38 to the portion 54 causes separation of the splice tape 50 along the longitudinally extending weakened section 25 defined by the cuts 28 and 29 and splicing of the following roll of web material 48 to the portion 54 of the leading roll of web material 56. The first, second and third adhesive layers 34, 36 and 38 exhibit an adhesion force in excess of a holding force exhibited at the weakened section 25 of the tape substrate 12 such that tape separation occurs at the weakened section 25. The stress cuts 29 (129 in the case of tape 110) direct the tape separation (i.e., tearing) away from the third adhesive layer 38 (138 in the case of tape 110) eliminating the possibility of any exposed areas of adhesive on the tape substrate 12 (112 in the case of tape 110) that could come into adverse contact with printing equipment. The stress cuts 129 in the case of tape 110 only, also direct the tape separation (i.e., tearing) away from the first adhesive layer 134 further eliminating the possibility of any exposed areas of adhesive on the tape substrate 112 that could come into adverse contact with printing equipment. The extension of the third adhesive layer 38 beyond the leading edge portion 44, facilitates adhesion of the third adhesive layer 38 to the portion 54 and thereby separation of the splice tape 10 at the cuts 28 and 29. The leading roll of web material 56 is then cut via a cutting mechanism 60. This flying splice adhesive tape 10, 110 can be processed through all the equipment on a printing line including sheeters and stackers. In addition, since the second and third adhesive layers are immediately adjacent to the plurality of cuts, the amount of unsecured splice tape tail is minimized which lessens the likelihood that the splice tape tails could jam in printing and finishing line equipment (such as sheeters and stackers) or catch in printing equipment affecting tracking of the web material, causing web material wrinkles, web breaks or tear offs that could affect final print quality. Moreover, this flyinq splice adhesive tape 10, 110 is applicable to a leading edge of web material, that is parallel to a longitudinal axis of the roll upon which the web material is contained, which reduces printing drum wear as the leading edge passes over the printing drum since leading edge forces are directed perpendicular to a printing drum generatrix which is parallel to a longitudinal axis of the drum. The nonangled leading edge also minimizes the amount of expiring web material free tail that could catch on and jam printing line equipment when compared to splice tape requiring an angled leading edge. In addition, since the third adhesive layer extends past the first adhesive layer, the splice tape 10, 110 presents a stepwise increase in splice tape thickness to the printing drums, which further reduces printing drum stresses that would otherwise exist if the first and third adhesive layers had the same starting point and presented an abrupt change in splice tape thickness to the printing drum. Using this splice tape 10, 110 with a following roll of web material having a leading edge portion that is parallel to the longitudinal axis of the roll allows tension to be applied uniformly across the web material when the "new-to-old" splice is made and as the splice travels through the printing, cutting and assembling machinery. Uniform web material tension reduces tension upsets thereby resulting in a straight tracking web material which reduces accidental web material breakage. In addition, since the tape 10, 110 is useable with a following roll of web material having a leading edge portion that is parallel to the longitudinal axis of the roll, less tape 10, 110 has to be applied to the leading edge, thereby reducing waste. Moreover, applying the tape 10, 110 to the leading edge portion of the roll of web material that is parallel to the roll axis is easier for both manual and automatic application when compared to applying a splice tape to an angled leading edge. The flying splice adhesive tape 10, 110 can be applied to the following roll of web material by hand, by a manually operable tape dispenser or by an automatic tape application apparatus such as described in United States Patent Application Serial No. 08/112,891 entitled APPARATUS AND METHOD FOR APPLYING ADHESIVE TAPE filed on 27 August 1993 and incorporated herein by reference thereto. When compared to the current system of manual application employing a plurality of paster tabs, paster tapes and splice flags, this splice tape 10, 110 can be accurately and consistently applied to a leading edge from one roll of web material to the next. Although the present invention has been described with reference to preferred embodiments, workers skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention. It is to be understood that the flying splice adhesive tape 10, 110 can be used with a leading edge portion of a following roll of web material that is cut at an angle of less than ninety degrees as measured between the leading edge and the roll off direction of the web material. In addition, it is to be understood that the third pressure sensitive adhesive layer 38, 138 of the flying splice adhesive tape 10, 110 may include adhesive free areas (i.e., areas of adhesive 38, 138 that are either deadened by the application of strips of material over the adhesive or to which no adhesive has been applied) so that the tape 10, 110 is useable with machinery employing a belt drive for the web material rolls such as disclosed in U.S. Patent 4,905,924 to Moore. WHAT IS CLAIMED IS; 1. A flying splice tape 10,110 for holding down a leading edge portion 44 of an outer layer 46 of a following roll of web material 48 and for facilitating the splicing of the leading edge portion to a portion 54 of a leading roll of web material 56 which is being advanced, the tape comprising: a tape substrate 12,112 having a first side 14,114 and a second side 16,116, the tape substrate having, on its first side, a first portion 18,118 adjacent a first edge of the tape substrate, a second portion 22,122 adjacent a second opposite edge 24,124 of the tape substrate, and an intermediate portion 26,126 therebetween, the intermediate portion having a weakened section; a first adhesive layer 34,134 on the first portion of the first side of the tape substrate, the first adhesive layer being spaced from the weakened section and extending towards the first edge of the tape substrate; a second adhesive layer 36,136 on the second portion of the first side of the tape substrate, the second adhesive layer being adjacent to the weakened section and extending towards the second edge of the tape substrate, the intermediate portion of the first side of the tape substrate being free of adhesive; and a third adhesive layer 38,138 on the second side of the tape substrate, the third adhesive layer extending from the weakened section towards the first edge of the tape substrate, with a remaining portion 40,140 of the second side of the tape substrate being free of adhesive. 2. The flying splice tape of claim 1 wherein the first longitudinal portion 18,118 is wider than the second longitudinal portion 22,122. 3. The flying splice tape of claim 1 wherein the first longitudinal portion 18,118 is wider than the intermediate longitudinal portion 26,126. 4. The flying splice tape of claim 1 wherein the intermediate longitudinal portion 26,126 is wider than the second longitudinal portion 22,122.

Claims: 5. The flying splice tape of claim 1 wherein weakened section is defined by a plurality of spaced cuts along the intermediate portion of the tape substrate. 6. The flying splice tape of claim 5 wherein the plurality of spaced cuts includes spaced V-shaped cuts 128 that extend through the tape substrate. 7. The flying splice tape of claim 6 wherein the plurality of spaced cuts further includes linear stress cuts 129 that extend through the tape substrate and are located between adjacent V-shaped cuts. 8. The flying splice tape of claim 6 wherein an apex of each V-shaped cut 128 is adjacent the second longitudinal portion 122. 9. The flying splice tape of claim 5 wherein the plurality of spaced cuts includes spaced linear main cuts 28 that extend through the tape substrate and are oriented substantially parallel to the first and second edges 20,24 of the tape substrate. 10. The flying splice tape of claim 9 wherein the plurality of spaced cuts further includes linear stress cuts 29 that extend through the tape substrate and are located between adjacent linear main cuts. 11. The flying splice tape of claim 10 wherein the linear main cuts are longer than the linear stress cuts. 12. The flying splice tape of claim 1 wherein the flying splice tape is wound on a roll, and further comprising an adhesive release liner removably affixed to the second side of the tape substrate. 13. The flying splice adhesive tape of claim 1 wherein the first, second and third adhesive layers exhibit an adhesion force in excess of a holding force exhibited by the weakened section of the tape substrate such that tape separation occurs at the weakened section.

Inventors: HALL PETER B, KOEBLER GOWER W, MCCORMICK MICHAEL O, HALL, PETER, B., KOEBLER, GOWER, W., MCCORMICK, MICHAEL, O.
Applicants: MINNESOTA MINING & MFG, MINNESOTA MINING AND MANUFACTURING COMPANY
Application year: 1994
Main classification: B65H19
IPC codes: B65H19